Contact Us: 1-440-250-1900

Continuous and Lost Foam Casting

There are several types of machined castings and the less discussed methods are continuous

and lost foam casting. Both have complicated technological processes and complex technical characteristics. Here are the facts on the two types of castings.

where can i get machined castings?

Why Choose These Types of Castings

Continuous Casting

It is a state-of-the-art casting method that involves the continuous pour of molten metal into a crystallizer. Once it solidifies, the casting is continuously pulled out from another end so the metal can obtain any specific length.

When it comes to technical characteristics, continuous casting can enhance production efficiency. Likewise, because of the simplified techniques, this process can dramatically reduce the desired production area and labor intensity. Another advantage why using continuous casting is recommendable is the fact that it offers good mechanical properties, uniform structure, and dense crystals.

Continuous castings are often applied in productions with cross-sectional shapes like pipes, rod billets, slabs, and ingots. This type of casting is also used in components made of magnesium alloys, aluminum alloys, copper alloys, iron, and cast steel.

Lost Foam Casting

Otherwise known as a solid casting, lost foam casting is a contemporary method that involves a combination of foam or paraffin models akin to the shape and size of the casting to produce a model cluster. After drying and brushing the refractory coating, it is buried in dry sand and poured under intense pressure to vaporize the model.

As for its technical characteristics, lost foam casting can reduce production costs and investment. It also offers a high degree of freedom during the production process, flexible design, and no parting surface.

As for application purposes, it works best in producing different sizes of precision castings with complicated structures. The best thing about this type of casting is that there are no restrictions on the kind of alloy used.

where can i get machined castings?

Learn More About the Other Types of Machined Castings

Apart from lost foam and continuous casting, there are also other types of casting processes such as squeezing die casting, vacuum die casting, and many more. Contact our experts at Ferralloy Inc. to know more!

Forgeability of a Metal

The ability of a metal to undergo deformation without cracking by means of forging is what experts call the forgeability of a metal. With this characteristic, metals can easily be formed with low force and resistance. For instance, closed die forging involves a process wherein the dies move toward each other by covering the metal. The heated raw material is placed at the bottom die to produce a design or shape according to specifications. To know more about the forgeability of the metal, please continue reading.

 

What is Closed Die Forging?

All about Forgeability

Tests to Determine Forgeability

According to experts, there are two primary tests to determine forgeability of a metal – Upsetting test and Hot-twist test. Upsetting test involves cracking while upsetting a cylindrical specimen.  Although this test only provides basic guidelines, it uses different strain and temperature rates to ensure that forgeability can be determined.

On the other hand, the hot-twist test requires the twisting of a metal rod at different temperature rates. Using this method, forgeability can be determined for various materials, including steel.

Extrusion Process

Extrusion is conducted by deforming metal and transporting it into a chamber before the compression process starts. In standard extrusion procedures, a round billet is placed in a chamber and forced through a die opening by a ram. Additionally, this process requires extreme temperature for the material to be completely formed.

The methods of extrusion involved in forgeability of a metal are direct extrusion, indirect extrusion, hydrostatic extrusion, and impact extrusion.

Metal Flow

Metal flow is an important factor to consider when deforming a metal. It must have a substantial reduction in the cross-sectional part of the process to make sure that the flow is undisturbed. Also, extrusion defects may occur if there are impurities and oxides caused due to the inhomogeneous flow of metal. When this happens, surface defects will thrust or be expelled into the center of the extruded parts.

 

What is Closed Die Forging?

More Information about Closed Die Forging and Extrusion

At Ferralloy Inc., we strive to provide answers for every inquiry! Contact us today if you have any questions and our friendly staff will be glad to answer them!

How Accurate is Investment Casting?

Investment casting is one of the first and most common types of metal components. The procedure to create these components involves pouring molten metal into a ceramic mold. The metal solidifies within the mold, and then the metal casting is broken out. Industries that focus on food equipment, railroad, heat treating, steel production and processing, coal mining, road construction, oil, aerospace, aircraft, and other countless industries discovered the benefits of this type of casting.

where is the best investment casting?

Accuracy of Investment Casting

Near Net Shape

Investment casting is extremely accurate and near net shape. Since metal components are created by using the same wax pattern, this accuracy can be maintained from casting to casting. Additionally, this process uses stainless steel, aluminum alloy, titanium alloy, or superalloy to create and yield precise metal components that can withstand high and low temperatures.

Additionally, near net shape manufacturing is an ideal solution for those wanting to save money as much as possible. This is because near-net-shape manufacturing does not require finishing steps. So, when you do not need any time for machining done, you can save on production costs.

Intricate Design

When using investment casting, engineers can design and create a lot to customize your product. Logos, product ID’s or numbers, letters, thru-holes, slots, blind holes, external and internal splines, gears, and thread profiles are just some of the intricacies that can be done.

Guarantees Product Quality

To ensure product quality, investment casting uses different methods such as coordinate measuring, ultrasonic, and dye penetrant. These methods will be used according to where the metal components will be used. Dye penetrant testing is a nondestructive method, and it includes cleaning the surface of a product, then applying a colored penetrant, or dye.

Ultrasonic testing is also nondestructive testing that works by sending high-frequency wavelengths through an object to detect cracks and other possible flaws. Lastly, coordinate measuring uses a probing system in the machine, and data collection allows for precision, which results in durability.

where can I get the best investment casting?

Where to Look for Investment Casting

It is important to ensure that any exact measurements are achieved in machined investment casting. At Ferralloy Inc., we have the experience and authority to provide this service and product to you. Contact us today!

Comparing Die Casting and Investment Casting Methods

Die casting, and investment casting are 2 of the foremost important types of casting. Die casting is a method wherein molten metal is created and formed into a mold cavity by way of enforcing high pressure. On the other side, investment casting is a process that involves the injection of wax into the aluminum cavity. Both die casting and investment castings have different advantages and disadvantages. Read on to know more.

where are the best investment castings?

How Does Die Casting Differ from Investment Casting?

Die Casting

As stated earlier, die casting differ from investment castings in such a way that the former involves a metal casting procedure. It is categorized by the use of a mold cavity to apply high pressure to the molten metal. These molds are then machined, designed, and created from higher strength alloys. Additionally, the majority of die castings are iron-free.

Among the notable advantages that clients opt to choose to die castings over investment castings are the following: it has an exceptional economic effect, high productivity, and creates good product quality.

Investment Castings

Investment castings involve an exact and strict casting process through the use of the lost-wax process to create components in the metal cast alloys. This process is known to be very accurate, creating components with accurate dimensions and smooth surface finishes. With this process, the machining and finishing processes are reduced. Thus, it will be more cost-effective without even compromising the quality. The only downside when choosing investment casting is that it is more expensive than sand casting.

Other Differences

Casting predominantly includes special casting and sand casting. Investment casting is included under special casting while die casting is considered pressure casting, which is another major type with the same level as investment castings. As for the cost, die casting costs are higher than investment casting since the former involves post-processing operations and high-processing costs. However, when large production is needed, die casting is recommended because investment casting is a manual process that requires more time and cost.

who sells the best investment castings?

Where to Get Die Casting or Investment Castings?

If you’re planning to get components or materials that underwent die casting or investment casting process, contact Ferralloy today for more inquiries!

Open Die Forging | Closed Die Forging vs. Open Die Forging

The forging industry has come a long way from using inefficient processes and antiquated applications. Today, we see forging engineering in various industries including machinery, construction, automotive, agricultural, oilfield equipment, and so much more. Although there are numerous options for metal deformation using the forging concept, the most widely-applied processes are closed and Open Die Forging.

 

The Difference Between Closed and Open Die Forging

 

  • Closed die forging is also called impression die forging. It’s a process that involves the compression of a piece of metal under high pressure in order to fill an enclosed die impression for the required shapes. Sometimes, a second forging operation is needed to achieve the shapes’ proper dimensions. Among the factors that determine the cost of a closed die forged part are the type of material, the need for heat treatment, and the tightness of tolerances.

 

In terms of application, closed die forging is commonly used for small critical parts such as forged fittings, forged automotive parts, forged lifting and rigging hardware, etc. because of its high precision. Its benefits include better surface finish, it requires little or no machining, no material limitation, cost-effective for large production runs, and the dimensions of net shapes and tighter tolerances are highly achievable.

 

  • Open die forging is also known as free forging or smith forging. It refers to the process of deforming a workpiece by placing it in between dies that are usually flat and don’t completely enclose the material. Through a series of continuous movements, the dies hammer the metal until the required shape is formed. This process is used for simple products in small quantities such as cylinders, rings, discs, and shafts.

 

This forging technique is found to be more appropriate for large parts in a number of tons. Examples of these parts include forged rollers, forged long shafts, and forged cylinders. The benefits of Open Die Forging include cost savings, minimal material waste, reduced chances of voids, reduced lead time, little or no tooling cost, finer grain size, continuous grain flow, longer part life, increased part strength, improved microstructure, and better fatigue resistance.

Open Die Forging

Ferroalloy is a reliable comprehensive engineering resource that offers total supply chain management to a diverse customer base on a global scale. If you want to gain a deeper insight between closed and Open Die Forging, contact us today.

Forgings | Closed Die vs Open Die Forgings

Forging is used in various industries such as construction, agriculture, and automotive. Two of the most commonly used forging methods are closed die forging and open die forging. Let’s take a look at the differences between these two forgings.

What Are Closed Die and Open Die Forgings?

Open die forging, also known as free forging, happens when metal billets are compressed under external compressive force and deformed to the desired dimensions or shapes in a free way without forging dies. Closed die forging, or impression die forging, is a process where the metal is heated by a medium frequency induction heating furnace to a high temperature and forged between upper and lower dies to get the expected shapes.

What Is the process?

Molding dies are predominantly made for closed die forging. Less, or no machining, is also used in closed die forging. For open die forging, enormous amounts of compressive force iareimposed but continuous strikes with a hammer to deform the metal billets.

How Are They Used?

Open die forging is used for large parts such as forged rollers, forged cylinders, and forged shafts. These products can be found in planes, trains, and automobiles. Closed die forging, however, is used for smaller parts due to its high precision. It is often used to make forged fittings, forged flange, and forged automotive parts.

Do You Need Forgings?

Ferralloy is a major supplier of open die and closed die forgings to a global customer base. Contact us today for more information about our closed die and open die forging capabilities.

Where do I find more information on forgings?

Investment Casting | What are the Different Methods of Machining?

Investment casting, forging, rolling, and more. There are so many ways that you can get the best out of your metal materials. Machining can do just that. Machining is a manufacturing process that cuts a component to specific dimensions that allows them to be even more precise. But, how do metalworkers machine materials?

Milling

A milling machine rotates at a very high speed. So, a metalworker will feed the workpiece into the machine and material will be cut away in small shapes. This is ideal for components that have features like holes, slots, and pockets.

Drilling

Metalworkers will use a drill bit to create a circular hole. So, drilling involves a rotary cutting tool and can perform anywhere from hundreds to thousands of rotations per minute. And, the machining will cut off little chips during this process.

Boring

Boring mills can come horizontally or vertically. Then, a metalworker can place a spindle in either orientation. Workers use this method to create clean and smooth finishes.

Facing

Facing cuts the face, or surface, of a component. This requires a planar, or flat, surface. So, the piece of metal rotates around one point. This allows for a nice and smooth face surface by removing material from the end of the piece.

Does Your Next Project Require Durable Investment Casting?

The integrity of your next industrial project relies on the durability of your metal components. At Ferralloy, we dedicate our time and expertise to creating the highest-quality metalwork. So, if you are interested in our investment casting capabilities or other services, contact us today to learn more!

should i machine my investment casting

Investment Casting | The History of the Term “Machining”

Precision is key when creating reliable metal components. Whether you are looking for an investment casting or something else, machining for an industrial project is a way to ensure accuracy of cuts. But term machining has not always meant the same thing in the metalworking industry.

As the technology of machining has changed, the definition of the term has as well. In the 18th century, a machinist simply would mean you could build or repair machines. This was done mostly by hand with forging and filing.

Later on – around the mid-19th century – “to machine” came around, as the practice became more widespread. This would include the use of more efficient tools like drill presses and sharp cutting tools.

Now, the term “machining” involves an array of modern day metalworking technologies. This can include electrical discharge machining, electrochemical machining, ultrasonic machining, and more. However, people refer to more traditional technology as “conventional machining.”

So, What is Machining?

Machining is the process used to cut and manipulate raw material for a finished product. It is a great way to ensure precision for unique shapes. Metalworkers use cutting, drilling, forming, grinding, and more to create a final component that is durable and accurate details.

Is Your Next Project in Need of Investment Casting?

Machining sometimes entails difficulties. So, it is important that metalworkers understand the investment casting process and machining process. At Ferralloy, we are experts on both. If you are in need of reliable castings and/or machining, we can assist you. Contact us today for more detail!

does my investment casting need machining

Open Die Forging | What Is the Process?

There are numerous different types of forging processes. There is rolled ring forging, which punches a hole in a thick, round piece of metal and then rolls and squeezes the part into a thin ring. There is also closed die forging, which moves two dies towards each other until they cover the work piece and create the desired part. Lastly, there is open die forging. However, you need to keep reading to learn more about this useful forging process!

The Open Die Forging Process

The open die forging process consists of deforming heated metal parts between a top die attached to a ram and a bottom die attached to a bolster, anvil, or hammer. The metal parts are worked at temperatures ranging from 500˚F to 2400˚F and are gradually configured into the desired shape through skillful pressing or hammering of the metal piece. This forging process often requires secondary machining and refining in order to achieve the tolerances for finished specifications.

Despite the need for additional machining, the open die forging process is extremely beneficial. The parts created by this process can range from simple to complex, including discs, sleeves, rings, cylinders, shaft, and more. It can even produce custom shapes. Furthermore, the repeated working of the material throughout the process increases the strength and grain structure of the finished product. Some other benefits of open die forgings include fatigue resistance and strength as well as reduction in voids.

If you are interested in using open die forging to create metal parts for your next project, contact us. Ferralloy, Inc. is a major supplier of open die, closed die, and rolled ring forgings to a global customer base. Our emphasis of quality guarantees that your forged parts will meet any and all of your specific requirements. Contact us today for more information about our forging capabilities!

Castings | What Are Sand Castings?

A casting is a type of metal component that is vital to countless industries. They are created through the casting process, which consists of pouring molten metal into a mold and then allowing it to cool and solidify. The casting process is extremely versatile and offers the freedom to form intricate metal parts. Due to the versatility of cast parts, there are a wide-range of casting types. Some popular casting types include investment castings, heat resistant castings, and sand castings. Today we will explain sand castings so you can decide whether or not these metal components can benefit your next project.

Sand Castings: Explained

A sand casting is different from other cast parts because it uses sand as the mold material. The sand is typically mixed with a bonding agent, such as clay, and is then moistening with water or another liquid in order to create the appropriate mold strength and plasticity. The surface of a sand casting might not be as smooth as other casting types. However, its rough surface and minor imperfections can be easily fixed with machining. Sand castings are one of the most common cast parts and can be utilized for both short-run and long-run productions. Some of the appealing advantages of this type of casting include its cost effectiveness, easy to change design, and manufacturing speed, just to name a few.

If you’re interested in using sand castings, or any other type of cast parts, for your next project, contact us. At Ferralloy, Inc. we can provide you with the highest quality metal components at a competitive price and delivered on time. If you are interested in learning more about our sand casting capabilities, or are interested in getting a quote for your next project, contact our international company today! We can answer your questions and help you get the best parts.